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Welcome
Day One
Hybrid System Overview
Transaxle Operation
Day Two
High Voltage System
Engine
Day Three
Brake System
Electric Power Steering
Air Conditioning
Multiplex Communication
Hybrid General Maintenance
Toyota is the
world leader in
hybrid technology.
1NZ-FXE Engine
HV Battery
Inverter
Hybrid Transaxle
Motor / Generator 1
Motor / Generator 2
Engine
HV Transaxle
- Motor Generator 1 (MG1)
- Motor Generator 2 (MG2)
071 Toyota Hybrid System 8
Hybrid System Engines
Highlander Hybrid
01 03 Prius1NZ-FXE (1.5L)
04 09 Prius.1NZ-FXE (1.5L)
10 up Prius2ZR-FXE (1.8L)
Highlander HV3MZ-FE (3.3L)
Camry HV....2AZ-FXE (2.4L)
Hybrid Transaxle
- MG1
- MG2
Rear Drive Unit
- MGR (shown)
HV Transaxle
- Motor Generator 1 (MG1)
- Motor Generator 2 (MG2)
071 Toyota Hybrid System 10
Hybrid Drivetrain Components
Highlander Hybrid
Inverter
Assembly
Inverter
Controls current to
motor generators
Also provides correct
voltages to other
systems.
HV Battery
HV Battery
Stores electrical
energy to drive
the system
ACC IG-ON
OFF READY
Walkaround
Test Drive
Low
temperature
indicator
light
MG1
Transaxle Damper
Resolver
Resolver
P112 P410
071 Toyota Hybrid System 33
Construction of MGR
Highlander Hybrid
Magnetized
Stator Side
Coil A
Coil B
Output
Rotor Side
Coil C
Oil Pump
(Mechanical) Transaxle Damper
MG1
Final Drive Gear
Final Driven Gear
Motor Speed
Reduction Planetary
Gear Unit
Power Split
Planetary Gear Unit
MG2 MG1
Engine
Counter
Driven Gear
(To Wheels)
Coil spring
Transaxle Damper
Filler Plug
(for ATF)
Adopts a shift
control actuator Oil pan is
discontinued & WS
type ATF is used
Fluid Type WS
0 to 0.20
in.
HV
ECU Engine
ECU
(ECM)
BEAN
Combination
Meter
Select Sensor
Shift Sensor
Cycloid Reduction
Mechanism
Stator &
Coil
Shift Control Actuator
Rotor
Rotation Angle
Sensor
Hybrid Transaxle
Parking Switch
Shift Control
Actuator Parking Lock
Mechanism
Request Control
T/M
HV ECU Control
ECU
P or Not P Position
Shift Lever
This will bypass the problem, allowing the vehicle to shut down.
Normal
EV Mode
ECO
Mode
1 Shift to N range
4
Lock Piece Slider
2
5
3 Shift Cable
CAUTION
This module does not certify you to work on hybrid vehicle high-voltage systems.
The Certified Technician must complete course 071 Toyota Hybrid System to
safely begin working on Toyota hybrid vehicles.
HV Battery
Inverter
2010-up Prius
Rear Drive
Unit (MGR)
Inverter
Assembly HV Battery
Camry Hybrid
DC-DC Converter
Battery ECU
HV Battery Module
HV Battery
Front Bus Bar Module
Module
SMR 1
HV Battery
(Battery Modules) Battery Smart
Unit
HV Battery
Cooling Blower
HV Junction
Block Assembly
HV Battery
Temperature Sensor
(for intake air)
CAUTION: The HV battery is a high-voltage component that only Certified Hybrid Technicians
should service.
071 Toyota Hybrid System 63
HV Battery State of Charge (SOC)
Overcharged region
Control
region
SOC
Undercharged region
Time
Lower SOC
control limit Target SOC control
SMRB
Service
Battery Modules
Plug
Resistor
SMRP
SMRG
HV Battery SMRP Precharge
Current Sensor Resistor
(+) to Inverter
Resistor
SMR1
Service Plug
High-
Voltage
Fuse
SMR3
(-) to Inverter
2001-2003
Prius 2004-2009 2010-up
Prius Prius
2007-2010
Camry Hybrid
2006-2007
Highlander Hybrid
HSD Inverter
MG ECU
Controls inverter
components
Boost Converter
288 VDC - 650 VDC
Inverter
AC - DC
DC-DC Converter
288 VDC - 12 VDC
Front
Back
Electrical insulating
gloves must be worn
when working with
Hybrid components.
4 36,000
Gloves that have been in-service for six months must either:
1.Be sent out for electrical testing or
2.Disposed of and replaced with new Gloves.
Before use, check the insulated gloves for cracks, tears and other
types of damage by performing the following procedure.
Use
Underwriters
Laboratories
approved CAT III
(1000V) test
equipment.
3
3 Steps to remove Large type Service Plug
2 1
High-voltage Condensers
Dis
cha
rge
0V
Electricity
Best Practices
Prevent conductive objects from completing the circuit between
energized conductors.
Do not use a universal joint. It can rotate accidentally &
complete a circuit.
Leaving the battery case open without the cover may expose
others to high voltage hazard. Never leave the HV battery
unattended with the cover off.
CAUTION:
Do not touch any bare cables that may have high-voltage.
Cover disconnected high-voltage connectors with insulating
vinyl tape
Dont touch!
04 09 Prius HV
Battery, 10 Prius HV
Battery, Camry HV
Battery, Highlander HV
Battery Assembly & Parts
Identification
After Potential
Repair Damage
START
Installation
Hydrogen
Vent Hose
2
2
Click is
heard
HV Systems
State of Charge (SOC)
Valve
To Intake
Manifold
EGR Cooler
MAP Sensor
(Vacuum Sensor)
Rotor
Shaft
Motor
From Radiator
To Radiator
Engine Engine
Coolant Combination Meter
Exhaust Gas
Rod
Gasket
Exhaust Pipe Gas
Control Stopper
Water Pump
(for heater)
Coolant Heat
Storage Tank
to/from
Water Valve
3.5 V (VLV4)
2.5 V
Specifications
Intake Pipes
Throttle Control
Motor
Throttle Position
Sensor
Surge Tank
Main Muffler
Cylinder Block
Drain Cock Plug
Radiator Drain
Cock Plug
Specifications
Fluid Toyota Super Long Life Coolant (SLLC)
Capacity 6.6 qt.
Fuel Sender
Mounting
Sub Tank
Steel Tank
Interior
Reed
Switch
Body Meter
Display
ECU ECU
Float
Combination Meter
Fuel Sender
Gauge
Inclination InclinationAmbient
Ambient
Sensors Temp. Sensors Sensor
Temp
Sensor
Fuel Fuel
Sender Sender
Main Tank Gauge Main Tank Gauge
01 03 Prius 04 09 Prius
Fresh Air
Line
01 03 Prius 04 09 Prius
Filler Pipe
Canister
Pump Module
Fuel Delivery
Pipe
12-hole Type
Fuel Injector
Vent Line
Fuel Filler Check Valve
Fuel Tank
[Pump Module]
ECM
Canister Pressure Sensor Charcoal
Canister
* The purge VSV control has changed and the purge flow volume
increased.
071 Toyota Hybrid System 141
Diagnostic Inspection Modes
Accelerator
Pedal IG-ON
OFF
READY
IG-ON ON
Brake Pedal
Stroke Sensor
Steering Angle
Sensor
2004 to 2009:
2010-up: Electronic Brake Actuator
Hydraulic Brake Booster 20012003: with Stroke Simulator
with Stroke Simulator Hydraulic Boosted
Master Cylinder
- Brake Assist
- ** TRAC
- - HAC -
- Enhanced VSC VSC
- - - VDIM
Drivers Demand
Braking Hydraulic
Force Braking Force
Regenerative
Braking Force
Time
Master Cylinder
Pressure Sensor
EPS
Skid Control ECU
THS-II
Regenerative
Hydraulic Power Hydraulic Control Brake Force
Source Portion Portion
Brake Force
Sensor Lever
SKS2
Voltage
SKS1
1
Brake Pedal
0
-15 0 60
Sensor Lever Rotational Angle
Brake Actuator
Skid Control ECU
2 Linear Solenoid Valves
4 Switching Solenoid Valves
8 Control Solenoid Valves
Pressure sensors for:
- Regulator
- Wheel Cylinder
Stroke - Accumulator
Simulator
Brake Actuator
Pump Motor
Fluid Level
Hydraulic Brake Booster
Warning
Switch
: Accumulator
Pressure Sensor
: Pressure Holding
Solenoid Valve
: Pressure Reduction
Solenoid Valve
FR LH FR RH RR LH RR RH
MAX Line
Fluid Level
Support Line
MIN Line
Capacitor Cell
EPS
DC motor
ECU
DC motor
Torsion
Bar
Detection Detection
Ring 3 Detection Ring 1
Ring 2
04 09 Prius
01 03 Prius
Gateway ECU
DLC3
DC Motor
V Bus No.1
: Models with brushless type power steering motor only (17inch wheels)
*
Combination
Switch Assembly
Do not remove the steering angle sensor from the Steering Angle
spiral cable Sensor
Do not replace or rotate the spiral cable with the
battery connected & engine switch ON
Combination Meter
EPS ECU
P/S Warning Light
THS ECU
THS ECU
READY signal
06 07 Highlander Hybrid
Highlander EPS
PTC
Heaters
Aluminum
PTC
Fin Brass
Element
Plate
Electrode
PTC Insulation
Element Film
From
Engine
04 09 Prius
From To
Bypass Valve Close Engine Heater
Solar Sensor
A/C Inverter
A/C ECU
Electric Room Temp. &
Compressor Humidity Sensor
Evap.
Temp. Clean Air Filter
Sensor
Blower Fan
Heater Core PTC Heater
ES27 compressor
Oil Separator
A/C Inverter
Motor
Shaft
Fixed Scroll
Discharge Port
Variable Scroll
Brushless Motor
ES18 compressor ES27 compressor
DC 201.6 V
Oil
Separator
Brushless
Motor
2010 Prius
Solar Ventilation System can operate indefinitely
as long as the operating conditions are met
regardless of ambient air temperature.
Remote Air Conditioning System will operate for
approximately 3 minutes.
Ventilation
Switch Solar Ventilation ECU
A/C Amplifier
Tips:
Turn the solar ventilation switch
OFF when servicing.
Cover the entire solar panel to
block sunlight.
Press
A/C System & Hold
Power
HV Battery
Plasmacluster
Generator
- +
+
-
-
+
+ - +
-
Positive and
Negative Ions
2010 Prius
Camry Hybrid
071 Toyota Hybrid System 189
Ejector Cycle System (ECS)
2010 Prius
Capillary Ejector
Tube
Condenser
Compressor
Expansion A A Cross Section
Valve
Top Tank
ECS Evaporator
Downwind Side
Ejector To Evaporator
(Upwind Side)
Nozzle
From Expansion
Valve
Mixing
Vacuum Portion
Diffuser
Portion
From Evaporator
(Downwind Side)
Contact Semiconductor
Relays Fuses Relays
Front
Power
Distributor
Mode Monitor
Terminal
Headlight Leveling
Actuator
Rear Height
Control Sensor (LH)
J/B
Junction Block
White-Black (W-B)
Light Green (LG)
Pink (P)
Sky Blue (SB)
Engine Oil 5W-30 (2,3) 5W-30 (2, 3) 0W-20 (6) 5W-30 5W-20(6)
(06-07)
0W-20 0W-20
(08-09)
Coolant LLC4) SLLC SLLC SLLC SLLC
Transaxle Fluid ATF T-IV WS ATF WS ATF WS ATF WS ATF
Compressor Oil ND8 ND11 (5) ND11 (5) ND11 (5) ND11 (5)
Notes:
1. Using a higher octane fuel may prevent normal engine operation.
2. Using a different oil viscosity (such as 10W-30) can cause oil to splash up into the intake manifold.
3. 2001 model specifies API Service SJ. 2002 and newer models specify API Service SL
4. SLLC can be used, however it does not extend the drain interval.
5. ND11 has electrical insulating properties & is the only compressor oil to be used.
6. SAE 5W-20 may be used. 0W-20 is the best choice for good fuel efficiency and good starting in cold weather.
01 03 Prius
Lead-calcium Alloy
01 03 Prius 04 09 Prius
Positive Jumper
Cable
01 03 Prius S34B20L
Special Smart charger:
S55D23L 00002-YA122-01*
Optional battery - See TSB EL014-03
Only perform a slow charge (3.5 A
04 09 Prius S34B20R or less).
www.techinfo.toyota.com